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N° 109-125 DA TE: December 13, 2007 REV. : A - October 19, 2020 Pa ge 1 of 9 TITLE INSPECTION OF THE TIP CAP P/N 709-0103-29-109 OF THE MAIN ROTOR BLADES P /N 709-0103-01-101/-105/-109
REVISION LOG Revision A of this Service Bulletin is issued to introduce the following modification:
- update the BT 109-125 to the new Service Bulletin template;
- eliminate the magnifying glass inspection prescribed in the first issue of this SB;
Helicopters which are already complying with the previous issue of this Service Bulletin or with Paragraph 62-10-25C of the applicable MM shall only apply the recurring inspection following the Accomplishment Instructions required by this revision without changing their current scheduling.
Revision bars in the outer margin identify changes.
An appropriate entry should be made in the aircraft log book upon accomplishment.
If ownership of aircraft has changed, please, forward to new owner.
Leonardo S.p.A.
Via Giovanni Agusta, 520 21017 Cascina Costa di Samarate (VA) Italy Tel.: +39 0331 229111 - Fax: +39 0331 229605/222595 ALERT
SERVICE BULLETIN
S.B. N°109-125 ALERT DATE: December 13, 2007 Page 2 of 9 REVISION: A - October 19, 2020
1. PLANNING INFORMATION A. EFFECTIVITY All the main rotor blades P/N 709-0103-01-101/-105/-109 installed on the Leonardo S.p.a. A109C helicopters (and/or stored as spare parts) equipped with tip cap P/N 709-0103-29-109.
B. COMPLIANCE Tip Cap P/N 709-0103-29-109 that have accumulated more than 600 (six hundred) flight hours:
Within and not later than 50 flight hours after the issue of this Service Bulletin.
Subsequently every 50 (fifty) flight hours.
Tip Caps P/N 709-0103-29-109 that have accumulated less than 600 (six hundred) flight hours:
Within and not later than 600 (six hundred) flight hours. Subsequently every 50 (fifty) flight hours.
C. CONCURRENT REQUIREMENTS N.A.
D. REASON This Service Bulletin is issued in order to provide the necessary instruction on how to perform the detailed inspection of Main Rotor Tip Cap Assy P/N 709-0103-29-109.
E. DESCRIPTION In 2007 some cases of loss of a part of the tip P/N 709-0103-29-109 of the main rotor blade P/N 709-0103-01 had been reported on an A109E helicopter model, with subsequent increase of helicopter vibratory level. The cause of this loss is the fracture of the welded bead (joint line of shells) of the tip leading edge. The action prescribed by first issue of this Service Bulletin (and subsequently added in the Maintenance Manual) consisted in a visual inspection with the aid of a 10x magnifying glass. In case of doubts about the presence of cracks and/or damage on the welded bead of the tip cap, it was prescribed to perform a detailed inspection with dye penetrant method. Recently, few cases of tip cap detachment have occurred, leading to the consideration that the visual inspection cannot be considered sufficiently conservative anymore. Thus, the Revision A of this SB, is issued to remove the magnifying glass inspection leaving the dye penetrant method as the only applicable one.
S.B. N°109-125 ALERT DATE: December 13, 2007 REVISION: A - October 19, 2020 Page 3 of 9 F. APPROVAL The technical content of this Service Bulletin is approved under the authority of DOA nr.
EASA.21.J.005. For helicopters registered under other Aviation Authorities, before applying the Service Bulletin, applicable Aviation Authority approval must be checked within Leonardo Helicopters customer portal.
EASA states mandatory compliance with inspections, modifications or technical directives and related time of compliance by means of relevant Airworthiness Directives.
If an aircraft listed in the effectivity embodies a modification or repair not LHD certified and affecting the content of this Service Bulletin, it is responsibility of the Owner/Operator to obtain a formal approval by Aviation Authority having jurisdiction on the aircraft, for any adaptation necessary before incorporation of the present Service Bulletin.
G. MANPOWER To comply with this Service Bulletin 3 (three) MMH are deemed necessary.
MMH are based on hands-on time and can change with personnel and facilities available.
H. WEIGHT AND BALANCE N.A.
I. REFERENCES
1) PUBLICATIONS
PARAGRAPH/SECTION DESCRIPTION PART PAR01 00-20-1 Helicopter safety - NOTE The following paragraph is referred to Overhaul Manual.
PARAGRAPH/SECTION DESCRIPTION PART PAR02 62-11-01 Main rotor blade -
2) ACRONYMS DOA Design Organization Approval EASA European Aviation Safety Agency IETP Interactive Electronic Technical Publications IPC Illustrated Parts Catalog
S.B. N°109-125 ALERT DATE: December 13, 2007 Page 4 of 9 REVISION: A - October 19, 2020 LHD Leonardo Helicopters Division MM Maintenance Manual MMH Maintenance Man Hours P/N Part Number PTUM Pictorial Tools Usage Manual
3) ANNEX N.A.
J. PUBLICATIONS AFFECTED A109C MM - Maintenance Manual K. SOFTWARE ACCOMPLISHMENT SUMMARY N.A.
S.B. N°109-125 ALERT DATE: December 13, 2007 REVISION: A - October 19, 2020 Page 5 of 9
2. MATERIAL INFORMATION A. REQUIRED MATERIALS
1) PARTS N.A.
2) CONSUMABLES The following consumable materials, or equivalent, are necessary to accomplish this Service Bulletin:
# Spec./LHD code number DESCRIPTION Q.TY NOTE PART 1 TT-N-95, Type II Aliphatic naphtha (C059) AR (2) - 2 ASTM D235 Cleaning solvent (C120) AR (1)(2) - 3 SAE-AMS-2644, Type II, Method C Dye Penetrant (C041) AR (2) - 4 SAE-AMS-2644, Form e, Type II Developer (C404) AR (2) - 5 Commercial Masking adhesive tape AR (2) - 6 Commercial Abrasive Paper (grit no. 320 or finer grit 300) AR (2) - Refer also to AMDI for the consumable materials required to comply with the MM Paragraphs referenced in the accomplishment instructions.
3) LOGISTIC MATRIX N.A.
NOTE
(1) Solvent (C120) is considered alternative at Solvent (C059).
(2) Item to procured as local supply.
B. SPECIAL TOOLS Refer to PTUM for the special tools required to comply with the MM Paragraphs referenced in the accomplishment instructions.
C. INDUSTRY SUPPORT INFORMATION WARRANTY: Owners/Operators who comply with the instructions of this Service Bulletin no later than the applicable date in the “Compliance” section will be eligible to receive REQUIRED MATERIALS on free of charge basis, except for Consumable Materials and Special Tools.
NOTE: Customers who fail to comply with the instructions in this Service Bulletin before the compliance date are not eligible for the aforementioned special policy.
Please Issue relevant MMIR Form to your Warranty Administration Dpt.
S.B. N°109-125 ALERT DATE: December 13, 2007 Page 6 of 9 REVISION: A - October 19, 2020 NOTE 1: In case of cracks found after inspection, as reported on Point 3.8 of this Service Bulletin, please kindly inform urgently LHD’s personnel and/or PSE, in order to receive all directives.
S.B. N°109-125 ALERT DATE: December 13, 2007 REVISION: A - October 19, 2020 Page 7 of 9
3. ACCOMPLISHMENT INSTRUCTIONS
GENERAL NOTES
a) Place an identification tag on all components that are re-usable, including the attaching hardware that has been removed to gain access to the modification area and adequately protect them until their later reuse.
b) All lengths are in mm.
NOTE The procedures reported below are applicable to each one of the four main rotor blades and does not require to remove it from the helicopter.
1. In accordance with MM Paragraph 00-20-1, prepare the helicopter on ground for a safe maintenance. Disconnect the battery, all electrical power sources and/or the external power supply.
NOTE Next step should be performed only at the first scheduled inspection.
NOTE This inspection does not require removal of the blade from the helicopter.
2. With reference to Figure 1 Detail A, on both uppe r and lower sides of the Main Rotor Tip Cap Assy P/N 709-0103-29-109 remove paint from the indicated area using abrasive paper grit n°320 or more fine. Mask surrounding painted areas using adhesive tape.
CAUTION The personnel in charge of colour contrast liquid penetrant inspection here required shall be qualified in accordance with standard EN4179/NAS410 or equivalent. The temperature of the blade and of the penetrant liquid must be between 4°C and 45°C.
3. Using the visible dye penetrant method, perform t he inspection of the welded bead on tip cap leading edge (joint line between the two metal shell) for presence of cracks as follows.
3.1 Thoroughly degrease the inspection area with a lint free clean cloth soaked with solvent. Leave the solvent evaporate completely.
S .B. N°109-125 ALERT DATE: December 13, 2007 Page 8 of 9 REVISION: A - October 19, 2020
3.2 Mask with adhesive tape the trailing edge inboard for 30 mm to avoid possible seepage of penetrant in the tip cap.
3.3 Apply the SAE-AMS-2644 Dye Penetrant to the inspection area extending approximately 5 mm inboard from trailing edge on both upper and lower sides.
Penetrant dwell time is 30 to 40 minutes.
3.4 Remove excess penetrant with a dry lint free cloth followed by a cloth dampened with solvent until the background colour has been completely removed.
NOTE Do not pour the solvent directly on the inspection area.
3.5 Apply a thin and uniform layer of SAE-AMS-2644 De veloper; 10 to 15 minutes later illuminate the inspection area to 1000 lux and inspect for presence of cracks.
3.6 Upon completion of the inspection clean the affected area with a clean lint free cloth followed by a cloth dampened with solvent.
NOTE The paint removed from the tip cap must not be restored.
3.7 If no presence of cracks is found on the main rot or blade tip cap return the blade to service.
3.8 In case of presence of cracks inform Design Authority and, in accordance to OM Paragraph 62-11-01, replace the Main Rotor Tip Cap P/N 709-0103-29-109.
4. Return the helicopter to a ready to flight condition and record for compliance with this Service Bulletin on the helicopter logbook.
5. Send the attached compliance form to the following mail box:
engineering.support.lhd@leonardocompany.com As an alternative, gain access to My Communications section on Leonardo WebPortal and compile the “Service Bulletin Application Communication”.
Figure 1 S.B. N°109-125 DATE: December 13, 2007 REVISION: A - October 19, 2020 Page 9 of 9
Remarks:
Information:
SERVICE BULLETIN COMPLIANCE FORM Date:
Number:
Revision:
Please send to the following address:
Telephone:
Fax:
B.T. Compliance Date:
Customer Name and Address:
Helicopter Model S/N Total Number Total Hours T.S.O.
LEONARDO S.p.A.
CUSTOMER SUPPORT & SERVICES - ITALY PRODUCT SUPPORT ENGINEERING & LICENSES DEPT.
Via Giovanni Agusta, 520 21017 Cascina Costa di Samarate (VA) - ITALY Tel.: +39 0331 225036 Fax: +39 0331 225988 We request your cooperation in filling this form, in order to keep out statistical data relevant to aircraft configuration up-to-date. The form should be filled in all its parts and sent to the above address or you can communicate the application also via Technical Bulletin Application Communication Section placed in Leonardo AW Customer Portal - MyCommunications Area. We thank you beforehand for the information given.